Wall system

ABSTRACT

A wall system ( 10 ) comprising a plurality of pilings ( 12 ) and a plurality of slabs ( 14 ) supported by the pilings ( 12 ). Both the pilings ( 12 ) and slabs ( 14 ) are preferably formed of concrete and may be imprinted with one or more patterns. The pilings ( 12 ) are preferably cylindrical and include a bottom section ( 22 ) and a top section ( 24 ) supported by the bottom section ( 22 ). The bottom section ( 22 ) is preferably buried substantially below grade, while the top section ( 24 ) is located substantially above grade. The top section ( 24 ) includes at least one vertical slot ( 26 ) extending upwardly from a ledge ( 28 ) located approximately at grade to an opening ( 30 ) in a top surface ( 32 ) of each piling ( 12 ). The ledge ( 28 ) supports opposing edges ( 34 ) of the slabs ( 14 ), such that lower edges ( 36 ) of the slabs ( 14 ) are supported substantially at grade.

RELATED APPLICATIONS

[0001] This application claims priority of a provisional patent application titled “QUICK SET RETAINING WALL”, Serial No.60/375,611 filed Apr. 24, 2002, hereby incorporated into the present application by reference.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The present invention relates to walls. More particularly, the present invention relates to a concrete wall system that minimizes hydraulic load, can be easily moved, and can be formed into almost any shape.

[0004] 2. Description of Prior Art

[0005] Current decorative and retaining walls are susceptible to hydraulic load because the walls are typically constructed by trenching for and pouring footings along the wall's path. Footings provide walls with stability; however, footings extend below grade thereby trapping rain water, irrigation water, and any other water to which they are exposed.

[0006] Such trapped water induces hydraulic load on footings and walls which may damage or weaken walls, eventually leading to failure and collapse. Failure can cause flooding from suddenly released water. Collapse can be dangerous to anyone in the vicinity from falling debris.

[0007] Furthermore, utility, landscaping, or similar work often requires trenches to be dug under walls. Current decorative and retaining walls are typically damaged or destroyed during such work, since current walls cannot be removed, once installed, without being damaged.

[0008] Finally, current decorative and retaining walls are limited in size, shape, and arrangement. Specifically, current decorative and retaining wall components are only available in discrete sizes and wall sections must commonly meet at pre-defined angles, which cannot be altered.

[0009] Accordingly, there is a need for an improved wall system that overcomes the limitations of the prior art.

SUMMARY OF THE INVENTION

[0010] The present invention overcomes the above-identified problems and provides a distinct advance in the art of walls. More particularly, the present invention provides a concrete wall system that minimizes hydraulic load, can be easily moved, and can be formed into almost any shape. The wall system broadly comprises a plurality of pilings and a plurality of slabs supported by the pilings. Both the pilings and slabs are preferably formed of concrete and may be imprinted with one or more patterns.

[0011] The pilings are preferably formed at a job site, as will be discussed in greater detail below. The pilings are preferably cylindrical, but may be virtually any shape, and include a bottom section and a top section supported by the bottom section. The bottom section is preferably buried substantially below grade, while the top section is located substantially above grade. While the bottom section is preferably completely solid, the top section includes at least one vertical slot. The vertical slot extends from a ledge located approximately where the bottom section meets the top section to an opening in a top surface of each piling. The ledge supports opposing edges of the slabs, such that lower edges of the slabs are supported substantially at grade.

[0012] The slabs may be formed at the job site or may be pre-formed at a manufacturing facility where such work may be done more efficiently. The slabs are preferably substantially flat and may be slid down into the vertical slots.

[0013] In use, holes are dug at substantially even intervals along a proposed path for the wall system. Piling forms are placed within the holes, such that a portion of the forms extend above the holes to form the top section of the pilings. Slot blocks are placed within the forms, such that the vertical slots will be formed in the pilings oriented along the proposed path of the wall system. Pattern mats may be placed into the forms, in order to imprint patterns on the pilings. Concrete is then poured into the forms in order to form the pilings. Once the concrete has hardened, the forms may be removed, along with the mats and the blocks.

[0014] The slabs are placed between the pilings with the opposing edges of the slabs sliding down into the vertical slots until the lower edges of the slabs rest upon the ledges. In this manner, the lower edges of the slabs are supported substantially at grade. With the lower edges supported substantially at grade, rain and/or flood water may seep under the slabs with little resistance, thereby minimizing hydraulic load on the wall system. Finally, top caps may be placed atop the pilings to cover the vertical slots.

[0015] The pilings may be arranged to follow virtually any proposed path for the wall system. For example, the proposed path may comprise a substantially straight line. Alternatively, the proposed path may comprise a curve, compound curve, or serpentine curve. Furthermore, the proposed path may comprise a zig-zag or other jagged abrupt path. The proposed path may even loop back on itself to form a circular or oval containment, such as a holding tank or pond. Finally, the proposed path may comprise any or all of the above elements.

[0016] A preferred second embodiment of the present invention is configured as a deck system. The deck system broadly comprises a plurality of pilings and a plurality of slabs supported by the pilings similar to the pilings and slabs of the preferred first embodiment of the present invention.

[0017] However, in the second embodiment, the pilings are preferably rectangular. Bottom sections of the pilings are preferably buried substantially below grade, while top sections of the pilings preferably extend less than one foot above grade. The top section includes at least one substantially horizontal slot. The horizontal slot includes a ledge located approximately where the bottom section meets the top section. The ledge supports opposing edges of the slabs, such that lower surfaces of the slabs are supported substantially at grade. The top section may extend above the horizontal slots or may terminate in a top surface flush with upper surfaces of the slabs.

[0018] In use, the pilings and the slabs are constructed in a manner similar to that used to construct the pilings and slabs described above, accounting for the differences described herein. For example, slot blocks are placed horizontally within piling forms in order to form the horizontal slots.

[0019] It should be noted that the slabs of any of the embodiments may be removed, as desired. For example, should utility or trenching work be required, any affected slabs may be removed, set aside while the work is being conducted, and then reinstalled once the work is completed. This feature prevents damage to the slabs otherwise commonly associated with such work.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] A preferred embodiment of the present invention is described in detail below with reference to the attached drawing figures, wherein:

[0021]FIG. 1 is a perspective view of a wall system constructed in accordance with a preferred first embodiment of the present invention;

[0022]FIG. 2 is a perspective view of a portion of the wall system;

[0023]FIG. 3 is a perspective view of a piling of the wall system;

[0024]FIG. 4 is a plan view of the piling;

[0025]FIG. 5 is a plan view of a deck system constructed in accordance with preferred second embodiment;

[0026]FIG. 6 is a vertical section view taken along line 6-6 of FIG. 5;

[0027]FIG. 7 is the view of FIG. 6 showing inclined slabs; and

[0028]FIG. 8 is the view of FIG. 6 showing offset slabs.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

[0029] Referring to FIG. 1, the preferred wall system 10 constructed in accordance with a preferred first embodiment of the present invention is illustrated. The wall system 10 broadly comprises a plurality of pilings 12 and at least one slab 14 supported by the pilings 12. Both the pilings 12 and slabs 14 are preferably formed of concrete and may be imprinted with one or more patterns. The pilings 12 are preferably formed at a job site, as will be discussed in greater detail below. While the slabs 14 may be formed at the job-site, the slabs may alternatively be preformed at a manufacturing facility where such work may be done more efficiently.

[0030] Referring also to FIGS. 2, 3, & 4, the patterns are preferably imprinted using commonly available pattern mats 16. Alternatively, the patterns may be imprinted using rubber pattern mats specifically designed for use with the wall system 10. For example, the rubber mats are reusable and readily accept adhesives in order to line forms, as will be discussed in further detail below. The patterns may be imprinted using a single continuous mat or several individual mats and may be identical for both the pilings 12 and the slabs 14. Alternatively the pilings 12 may be imprinted with one pattern, while the slabs 14 are imprinted with another pattern. Furthermore, the slabs 14 may be imprinted with a first pattern on a front side 18 and a second pattern on a back side 20. Finally, the pilings 12, either of the sides 18,20 of the slabs 14, or all three may be blank with no pattern imprinted thereon.

[0031] The pilings 12 are preferably cylindrical, but may be virtually any shape, such as rectangular, square, oblong, triangular, hexagon, octagon, or pentagon. The pilings 12 include a bottom section 22 and a top section 24 supported by the bottom section 22. The bottom section 22 is preferably buried substantially below grade, while the top section 24 is located substantially above grade. While the pilings 12 may be virtually any size, the pilings' diameter and height are dependant up the wall system's 10 size. For example, a ten foot tall wall system will require larger pilings 12 than a four foot tall wall system. In either case, the bottom section 22 is sized to support the wall system's 10 weight and the top section 24 is sized to match the wall system's 10 height. For example, in one embodiment, the pilings 12 are approximately eight foot tall and approximately eighteen inches in diameter. Alternatively, the ten foot tall wall system would include an approximately ten foot tall bottom section, an approximately ten foot tall top section, and the pilings would preferably be approximately thirty inches in diameter.

[0032] While the bottom section 22 is preferably completely solid, the top section 24 includes at least one vertical slot 26. The vertical slot 26 is approximately six inches deep and approximately four inches wide. The vertical slot 26 extends from a ledge 28 located approximately where the bottom section 22 meets the top section 24 to an opening 30 in a top surface 32 of each piling 12. The ledge 28 supports opposing edges 34 of the slabs 14, such that lower edges 36 of the slabs 14 are supported substantially at grade.

[0033] As discussed above, the pilings 12 may have one or more vertical slots 26. For example, if an end piling is to be used at an end of the wall system 10 the end piling may include only one vertical slot 26. Alternatively, if a successive piling is to be used along a proposed path of the wall system 10, the successive piling preferably includes two vertical slots 26. Furthermore, if a junction piling is to be used at a junction of wall systems the junction piling may include three or more vertical slots 26. However, most pilings 12 are expected to be used along the proposed path of the wall system 10 and have two vertical slots 26.

[0034] The vertical slots 26 may be arranged at any angle with respect to each other in order to align the slabs 14 with the proposed path of the wall system 10. For example, at a ninety degree corner of the wall system 10, two vertical slots 26 will be arranged at approximately ninety degrees with respect to each other such that corresponding slabs 14 would be aligned at approximately ninety degrees to each other and follow the proposed path of the wall system 10. This permits the wall system 10 to be formed into almost any shape.

[0035] For example, the proposed path may comprise a substantially straight line. Alternatively, the proposed path may comprise a curve, compound curve, or serpentine curve. Furthermore, the proposed path may comprise a zig-zag or other jagged abrupt path. The proposed path may even loop back on itself to form a circular or oval containment. In this case, the wall system 10 may be lined and used as a tank or pond. Finally, the proposed path may comprise any or all of the above elements.

[0036] As shown in FIG. 4, the pilings 12 are constructed using commonly available piling forms 38 of appropriate dimensions, as discussed above. The mats 16 may be placed inside the piling forms 38 in order to imprint the pilings 12 with one of the patterns. The vertical slots 26 are formed by placing slot blocks 40 vertically within the piling forms 38. The blocks 40 may be constructed from foam, wood, plastic, or any other suitable material. Once the piling forms 38 are prepared with the mats 16 and the blocks 40, as desired, concrete is poured therein. Once the concrete has hardened, the piling forms 38, the mats 16, and blocks 40 are removed leaving the pilings 12 with the pattern and the vertical slots 26 therein.

[0037] The slabs 14 are preferably substantially flat and approximately four inches thick, and thereby may be slid down into the vertical slots 26. The slabs 14 are sized to match the wall system 10. For example, the ten foot tall wall system would include approximately ten foot tall slabs. While the slabs 14 may be designed to virtually any length, the slabs 14 are preferably between six and eighteen feet long. For example, the ten foot tall wall system would include approximately twelve foot long slabs.

[0038] The slabs 14 may be formed like a sidewalk. For example, rectangular forms may be constructed along the ground with bulkheads placed between successive slabs. Concrete may be poured into the rectangular forms. Once the concrete has hardened, the rectangular forms may be removed. Then, the slabs 14 may be lifted and set into place between the pilings 12.

[0039] The wall system 10 preferably also includes a plurality of top caps 42 that fit over the top section 24 of the pilings 12 and cover the openings 30 of the vertical slots 26. The caps 42 may be imprinted with one of the patterns or may be left blank. The caps 42 are preferably between one inch and four inches thick with a diameter sized to match the pilings' 12 diameter. For example, the ten foot tall wall system, with approximately thirty inch diameter pilings, would include approximately thirty inch diameter caps.

[0040] In use, holes are dug at substantially even intervals along the proposed path for the wall system 10. For example, the ten foot tall wall system would require the holes to be spaced at approximately twelve feet and eighteen inches on center. The intervals are determined by the pilings' 12 diameter, the slots' 26 depth, and the slabs' length 14. For instance, the above eighteen inches represents a measurement from either opposing edge 34 of the slabs 14 to a center of the pilings 12, multiplied by two in order to account for both pilings 12 upon which each slab 14 will rest. More specifically, the above eighteen inches is calculated as the pilings' 12 fifteen inch radius minus the slot's 26 six inch depth multiplied by two.

[0041] The piling forms 38 are placed within the holes, such that a portion of the piling forms 38 extend above the holes to form the top section 24 of the pilings 12. The mats 16 are placed into the piling forms 38, in order to imprint the pilings 12 with one or more of the patterns, if desired. The blocks 40 are placed within the piling forms 38, such that the vertical slots 26 will be formed in the pilings 12 oriented along the proposed path of the wall system 10. Concrete is then poured into the piling forms 38 in order to form the pilings 12. Once the concrete has hardened, the piling forms 38 may be removed, along with the mats 16 and the blocks 40. Some minor trimming or shaping may be required around the vertical slots 26, since concrete may seep around the blocks 40.

[0042] At this point, the pilings 12 are substantially finished. The holes are preferably filled in and the job site may be brought to final grade. Alternatively, the job site may be left ungraded until after the slabs 14 have been installed.

[0043] The slabs 14 are placed between the pilings 12 with the opposing edges 34 of the slabs 14 sliding down into the vertical slots 26 until the lower edges 36 of the slabs 14 rest upon the ledges 28. In this manner, the lower edges 36 of the slabs 14 are supported substantially at grade, since the ledges 28 are located where the bottom section 22 meets the top section 24 and substantially at grade. With the lower edges 36 supported substantially at grade, rain and/or flood water may seep under the slabs 14 with little resistance, thereby minimizing hydraulic load on the wall system 10. Finally, the caps 42 are placed atop the top surfaces 32 of the pilings 12 to cover the openings 30 of the vertical slots 26.

[0044] As shown in FIG. 2, the wall system 10 is preferably backfilled with drainage rock 52 in order to facilitate water drainage. The drainage rock 52 is preferably placed behind the slabs 14, below the slabs 14, or both. Such a configuration allows the wall system 10 to act as a sea wall holding back soil and/or other material while allowing a relatively free flow of water. For example, when configured as a sea wall, the wall system 10 may prevent erosion by holding the drainage rock 52 in place, which in turn holds the soil.

[0045] Furthermore, the wall system 10 may be used as a retaining wall. For example, the proposed path may encircle an elevated area. Once the wall system 10 is in place, any space between the wall system 10 and the elevated area may be back filled with the drainage rock 52 in order to buttress the elevated area and provide proper drainage from the elevated area.

[0046] Alternatively, the wall system 10 may be used as a holding tank, such as those found at sewage treatment facilities. In this case, the proposed path preferably forms either the circle or the oval discussed above. Once the wall system 10 is in place, a liner is preferably installed. In this case, the liner acts to retain water, or whatever is intended to be held in the holding tank, while the wall system 10 reinforces and holds the liner.

[0047] Referring to FIGS. 5-6, a deck system 110 in accordance with a preferred second embodiment of the present invention is illustrated. The deck system 110 broadly comprises a plurality of pilings 112 and a plurality of slabs 114 supported by the pilings 112. The pilings 112 and the slabs 114 are similar to the pilings 12 and slabs 14 of the preferred first embodiment of the present invention.

[0048] However, the pilings 112 of the second embodiment are preferably rectangular having a length substantially equal to the deck system's 110 width. A bottom section 122 of each piling 112 is preferably buried substantially below grade, while a top section 124 of each piling 112 preferably extends less than one foot above grade. The top section 124 includes at least one substantially horizontal slot 126, instead of the vertical slot 26 of the preferred first embodiment. The horizontal slot 126 includes a ledge 128 located approximately where the bottom section 122 meets the top section 124. The ledge 128 supports opposing edges 134 of the slabs 114, such that lower surfaces 136 of the slabs 114 are supported substantially at grade. The top section 124 may extend above the horizontal slots 126 or may terminate in a top surface 132 flush with upper surfaces 150 of the slabs 114.

[0049] In use, the pilings 112 and the slabs 114 are constructed in a manner similar to that used to construct the pilings 12 and slabs 14 described above, accounting for the differences described herein. For example, slot blocks are placed horizontally within piling forms in order to form the horizontal slots 126.

[0050] Referring also to FIG. 7, the deck system 110 may be used as a culvert. For example, slabs 114 may be installed at an incline with respect to other slabs. In this manner, the deck system 110 may form a channel to direct water flow. The patterns may be especially useful in this case. For example, the patterns may be particularly abrupt, and thereby act to slow the flow of water. Referring to FIG. 8, slabs of the deck system 110 may be offset with respect to other slabs. In this case, the deck system 110 may take on a stair-step appearance. Such a configuration may also be used to control the flow of water.

[0051] While the deck system 110 has been described as being configured substantially horizontally, the entire deck system 110 may be constructed at an angle. For example, the deck system 110 may be used as part of an abutment for overpasses or other bridges. In this case, the pilings 112, are preferably aligned down a face of the abutment, such that the slabs 114 may be slid into place down the face and between the pilings 112. Alternatively, the pilings may be aligned across the face of the abutment, such that the slabs 114 are slid into place across the face and between the pilings 112.

[0052] The pilings 12,112 and/or the slabs 14,114 are preferably reinforced with re-bar, as required. For example, as shown in FIGS. 3 and 4, vertical re-bar 54 preferably extends substantially the entire height of the pilings 12,112 to structurally tie the bottom section 22,122 to the top section 24,124. Additional re-bar 56, may be used to tie the vertical re-bar 54 together, further adding to the structural integrity of the pilings 12,112. Similar re-bar techniques may be used for the slabs 14,114. With the re-bar 54,56, the wall system 10 and the deck system 110 may be designed to withstand significant structural load, such as that associated with holding tanks, sea walls, retaining walls, culverts, and abutments, while still allowing proper drainage in order to minimize hydraulic load on the wall system 10 or the deck system 110.

[0053] It should be noted that the slabs 14,114 may be removed, as desired. For example, should utility or trenching work be required, any affected slabs may be removed, set aside while the work is being conducted, and then reinstalled once the work is completed. This feature prevents damage to the slabs 14,114 otherwise commonly associated with such work.

[0054] While the present invention has been described above, it is understood that other materials and/or dimensions can be substituted. For example, the wall system 10 may be installed between two areas with two significantly different grades, thereby acting as the retaining wall. In this case, the lower edges 36 of the slabs 14 are preferably supported substantially at a lowest one of the two grades. Alternatively, the wall system 10 may be installed between two areas with substantially identical grades, thereby acting as a decorative or privacy wall. Additionally, the pilings 12,112 may be tapered such that the bottom section 22,122 is wider than the top section 24,124. The concrete may also be tinted using commonly available concrete coloring products. Furthermore, concrete or mortar may be poured into the slots 26,126 after the slabs 14,114 have been installed in order to hold the slabs 14,114 firmly in place. Concrete or mortar may similarly be used to hold the caps 42 in place. Finally, the slots 26,126 may include tapered sidewalls, as shown in FIG. 3, or squared sidewalls, as shown in FIG. 4. These and other minor modifications are within the scope of the present invention. 

Having thus described preferred embodiments of the invention, what is claimed as new and desired to be protected by Letters Patent includes the following:
 1. A wall system comprising: a plurality of pilings each having a bottom section for installation substantially below grade and a top section for installation substantially above grade, wherein the top section includes at least one vertical slot that terminates in a ledge approximately where the bottom section meets the top section; and at least one substantially flat slab for installation between two of the pilings, fitting into the slots therein and supported by the ledges, such that a lower edge of the slab is supported substantially at grade in order to minimize hydraulic load on the system.
 2. The system as set forth in claim 1, wherein the vertical slot extends through the top section and terminates in an opening at a top surface of the top section of the pilings.
 3. The system as set forth in claim 2, wherein the slab is in slid into place down through the opening to the ledge.
 4. The system as set forth in claim 2, further including a plurality of top caps that fit over the top surface and cover the openings of the slots.
 5. The system as set forth in claim 1, wherein the pilings are imprinted with a pattern using a reusable rubber pattern mat.
 6. The system as set forth in claim 1, wherein the slab is imprinted with a pattern.
 7. The system as set forth in claim 1, wherein the slab is imprinted with a first pattern on a front side and a second pattern on a back side.
 8. The system as set forth in claim 1, wherein the pilings and the slab are constructed of poured concrete.
 9. The system as set forth in claim 8, wherein the pilings are constructed at a job site along a proposed path of the system.
 10. The system as set forth in claim 1, wherein the slots are arranged along a proposed path for the system.
 11. The system as set forth in claim 1, wherein the pilings are constructed by: digging holes for the pilings at substantially even intervals along a proposed path for the system; placing piling forms within the holes, such that a portion of the piling forms extends above the holes in order to form the top section; placing slot blocks within the piling forms, such that the vertical slots will be formed in the top section of the pilings arranged along the proposed path for the system; and pouring concrete into the piling forms in order to form the pilings.
 12. A deck system comprising: a plurality of horizontally elongated pilings each having a bottom section for installation substantially below grade and a top section for installation substantially above grade, wherein the top section includes at least one horizontal slot forming a ledge approximately where the bottom section meets the top section; and at least one substantially flat slab for installation between two of the pilings, fitting into the slots therein and supported by the ledges, such that a lower surface of the slab is supported substantially at grade.
 13. The system as set forth in claim 12, wherein the horizontal slot extends across the top section.
 14. The system as set forth in claim 12, wherein the slab is imprinted with a pattern.
 15. The system as set forth in claim 12, wherein the pilings and the slab are constructed of poured concrete.
 16. The system as set forth in claim 15, wherein the pilings are constructed on-site along a proposed path of the system.
 17. The system as set forth in claim 12, wherein the pilings are constructed by: digging holes for the pilings at substantially even intervals along a proposed path for the system; placing piling forms within the holes, such that a portion of the piling forms extends above the holes in order to form the top section; placing slot blocks within the piling forms, such that the horizontal slots will be formed in the top section of the pilings arranged along the proposed path for the system; and pouring concrete into the piling forms in order to form the pilings.
 18. A method of installing a wall system comprising the steps of: digging holes for pilings at substantially even intervals along a proposed path for the system; placing piling forms within the holes, such that a portion of the piling form extends above the holes; placing slot blocks within the piling forms, such that slots will be formed in the pilings arranged along the proposed path for the system; pouring concrete into the piling forms in order to form the pilings; removing the forms and the slot blocks from the pilings after the concrete has hardened; and placing preformed concrete slabs between the pilings with opposing edges of the slabs fitting within the slots, such that lower edges of the slabs are supported substantially at grade thereby minimizing hydraulic load on the system.
 19. The system as set forth in claim 18, wherein the slab is imprinted with a pattern.
 20. The system as set forth in claim 19, further including the step of inserting a pattern mat into the forms before the concrete is poured into the forms in order to imprint the pilings with the pattern. 